US8093711B2 - Semiconductor device - Google Patents
Semiconductor device Download PDFInfo
- Publication number
- US8093711B2 US8093711B2 US12/364,340 US36434009A US8093711B2 US 8093711 B2 US8093711 B2 US 8093711B2 US 36434009 A US36434009 A US 36434009A US 8093711 B2 US8093711 B2 US 8093711B2
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- Prior art keywords
- semiconductor chip
- metal layer
- main face
- semiconductor
- encapsulation material
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- 239000004065 semiconductor Substances 0.000 title claims abstract description 150
- 229910052751 metal Inorganic materials 0.000 claims abstract description 68
- 239000002184 metal Substances 0.000 claims abstract description 68
- 239000000463 material Substances 0.000 claims abstract description 63
- 238000005538 encapsulation Methods 0.000 claims abstract description 57
- 238000000034 method Methods 0.000 claims description 18
- 229910052710 silicon Inorganic materials 0.000 claims description 17
- 239000010703 silicon Substances 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 230000008878 coupling Effects 0.000 claims 2
- 238000010168 coupling process Methods 0.000 claims 2
- 238000005859 coupling reaction Methods 0.000 claims 2
- 238000012372 quality testing Methods 0.000 claims 1
- 239000010410 layer Substances 0.000 description 31
- 229910000679 solder Inorganic materials 0.000 description 5
- 239000000758 substrate Substances 0.000 description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 239000012790 adhesive layer Substances 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000000708 deep reactive-ion etching Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
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Definitions
- a semiconductor package provides a protective enclosure for one or more semiconductor chips and includes interconnects to the chip(s).
- Semiconductor packages are employed in mobile electronic devices, including cellular telephones and other communication devices, automotive electronics, as well as other technology platforms.
- Some semiconductor packages are configured to be compatible with package-on-package stacking technologies in which a separate electronic component is stacked on a base package.
- package-on-package stacks include the base package fabricated to include landing pad(s) that receive/connect an upper package with semiconductor chip(s) in the base package. It is desirable to provide package-on-package semiconductor stacks with improved interconnect geometry and in a manner that does not deleteriously increase the base package size.
- One embodiment provides a semiconductor device including a semiconductor chip having a through-connection extending between a first main face of the semiconductor chip and a second main face of the semiconductor chip opposite the first main face, encapsulation material at least partially encapsulating the semiconductor chip, and a first metal layer disposed over the encapsulation material and connected with the through-connection.
- FIG. 1 is a schematic cross-sectional view of a semiconductor device according to one embodiment.
- FIG. 2 is a schematic cross-sectional view of another semiconductor device according to one embodiment.
- FIG. 3 is a block diagram of a process for manufacturing a semiconductor device according to one embodiment.
- FIGS. 4A-4D are schematic cross-sectional views of a process for manufacturing a semiconductor device according to one embodiment.
- FIG. 5 is a schematic cross-sectional view of multiple semiconductor chips encapsulated by material, with each chip including a through-silicon via according to one embodiment.
- FIG. 6 is a schematic cross-sectional view of an embedded wafer level package including a semiconductor chip formed to include a through-silicon via encapsulated by material, with a through-mold via formed through the encapsulation material according to one embodiment.
- FIG. 7 is a schematic cross-sectional view of a package-on-package stack according to one embodiment.
- Embodiments provide an embedded wafer level base package including at least one semiconductor chip formed to include at least one through-connection or through-silicon via extending through the chip.
- the package is fabricated to include a lower metal layer configured for attachment to an electronic board, for example a lower redistribution layer that is attached to a printed circuit board by a solder ball.
- the package includes an upper metal layer that forms a landing pad configured to receive another package in a stacked package-on-package configuration.
- the through-connection enables vertical and three-dimensional interconnection in the embedded wafer level base package.
- Embodiments provide embedded wafer level packages configured for package-on-package stacking that eliminates the use of expensive substrates common to ball grid array packages.
- the through-connections formed as through-silicon vias in the semiconductor chip eliminates the use of long metal wires that are employed to connect conventional side-by-side or two-dimensional chips together.
- the embedded wafer level base package including the through-silicon via provides Z-directional electrical connection through the semiconductor chip for improved radio-frequency performance with lower power consumption.
- the embedded wafer level package including chips with one or more through-silicon vias provide a reduced package size and reduced package thickness.
- FIG. 1 is a schematic cross-sectional view of a semiconductor device 20 according to one embodiment.
- Semiconductor device 20 includes a semiconductor chip 22 formed to include a through-connection 24 , encapsulation material 26 at least partially encapsulating semiconductor chip 22 , and a first metal layer 28 disposed over encapsulation material 26 and connected with through-connection 24 .
- semiconductor chip 22 includes a first main face 30 opposite a second main face 32 , where through-connection 24 extends between first main face 30 and second main face 32 .
- first main face 30 includes an active surface of semiconductor chip 22 that is provided with active surface connections.
- second main face 32 of semiconductor chip 22 provides another active surface of semiconductor chip 22 and includes active surface connections.
- an opening 34 is formed through encapsulation material 26 and a dielectric layer 36 to enable first metal layer 28 to connect with through-connection 24 .
- semiconductor chip 22 is a logic chip, or a memory chip, or another form of a suitable semiconductor chip.
- Suitable semiconductor chips include integrated circuits configured as logic circuits, control circuits, microprocessors or microelectrical-mechanical components, memory chips, power semiconductor chips such as power transistors, power diodes, insulated gate bi-polar transistors, vertical chips configured such that electric current flows in the Z-direction between main faces 30 / 32 , embedded chips, or flip chips.
- chip 22 is provided as a vertical power transistor having a first electrode connected to one of a source/drain on first main face 30 and a second electrode connected to the other of the source/drain on second main face 32 .
- though-connection 24 is formed as a through-hole ( 112 in FIG. 4A ) that is filled with metal, such as copper, gold, silver, aluminum, or alloys of these metals, or other electrically conducting metals.
- Through-connection 24 provides for electrical communication between main faces 30 , 32 of semiconductor chip 22 and is configured to provide enhanced radio-frequency performance with reduced power consumption by shortening the connection length through the thickness (or Z-direction) of device 20 .
- Suitable processes for forming an opening through the silicon portion of semiconductor chip 22 include deep silicon etching (DRIE) or laser drilling.
- DRIE deep silicon etching
- Encapsulation material 26 includes material that is generally non-electrically conducting. Suitable material for encapsulation material 26 includes polymers and/or epoxies. In one embodiment, dielectric 36 is deposited on encapsulation material 26 and suitably patterned (opened) for connection of first metal layer 28 with through-connection 24 . In one embodiment, encapsulation material 26 is disposed around semiconductor chip 22 over second main face 32 , leaving first main face 30 uncovered such that encapsulation material 26 is co-planar with first main face 30 .
- FIG. 2 is a schematic cross-sectional view of another semiconductor device 40 according to one embodiment.
- Semiconductor device 40 includes a semiconductor chip 42 formed to include multiple through-silicon vias (TSV) 44 a, 44 b, encapsulation material 46 at least partially encapsulating semiconductor chip 42 , and a metal layer 48 a connected with TSV 44 a and a metal layer 48 b connected with TSV 44 b.
- TSV through-silicon vias
- TSV 44 a, 44 b are formed to extend through semiconductor chip 42 between a first main face 50 and a second main face 52 .
- openings 54 are formed extending through a potion of encapsulation material 46 and an upper dielectric layer 56 a to enable connection of metal layers 48 a, 48 b with a respective one of TSV 44 a, 44 b.
- device 40 includes a lower dielectric layer 56 b that is patterned to enable metal layer 60 a to connect with TSV 44 a and metal layer 60 b to connect with TSV 44 b .
- Device 40 thus includes first metal layers 48 a, 48 b connected with a respective one of TSV 44 a, 44 b and second metal layers 60 a, 60 b connected with a respective one of TSV 44 a, 44 b.
- first metal layers 48 a, 48 b provide landing pads configured to receive and electrically connect with another package placed on device 40 .
- metal layers 60 a, 60 b are connected with a printed circuit board, for example through connecting elements 70 such as solder balls.
- TSV 44 a, 44 b provide three-dimensional electrical connection through semiconductor chip 42 with enhanced radio frequency performance and reduced power consumption.
- device 40 includes one or more through-mold vias 74 that are formed to extend between opposed major surfaces 80 , 82 of encapsulation material 46 .
- Through-mold vias (TMV) 74 provide vertical electrical connection through device 40 .
- TSV 44 a is fabricated to include a width W 1 and TMV 74 is fabricated to include a width W 2 , where the width W 1 of TSV 44 a is less than the width W 2 of TMV 74 .
- device 40 is provided as a logic device configured for use as a base package in a package-on-package system.
- device 40 is a logic device, a memory device, or other suitable semiconductor package.
- FIG. 3 is a block diagram 100 of a process for manufacturing a semiconductor device according to one embodiment.
- Process 100 includes providing a semiconductor chip at 102 .
- At 104 at least one through-connection is formed to extend between a first main face of the semiconductor chip and an opposing second main face of the semiconductor chip.
- the first main face of the semiconductor chip is placed on a carrier.
- encapsulation material is applied over the semiconductor chip and the carrier. In one embodiment, the first main face is not covered by encapsulation material since the first main face is in contact with the carrier.
- the carrier is removed from the semiconductor chip and the encapsulation material.
- Embodiments of process 100 provide a manufacturing approach for embedded or fan-out wafer level package assembly, as further described below.
- FIGS. 4A-4D provide schematic cross-sectional views of the fabrication of semiconductor device 20 ( FIG. 1 ) according to one embodiment.
- FIG. 4A is a schematic cross-sectional view of semiconductor chip 22 including openings 112 that are filled with electrically conducting material to form though-connection 24 .
- Through-connection 24 extends between first main face 30 and second main face 32 of chip 22 .
- FIG. 4B is a schematic cross-sectional view of first main face 30 of chip 22 placed on a carrier 120 .
- carrier 120 includes a carrier substrate 122 and an adhesive layer 124 disposed on substrate 122 .
- Carrier substrate 122 includes metal, plastic, paper, laminate or other suitable substrates for carrying chip 22 . Chip 22 is picked and placed in position on adhesive layer 124 of carrier 120 .
- FIG. 4C is a schematic cross-sectional view of encapsulation material 26 disposed over carrier 120 to at least partially encapsulate chip 22 .
- encapsulation material 26 is injection molded over chip 22 and onto carrier 120 .
- encapsulation material 26 is compression molded over chip 22 and onto carrier 120 .
- encapsulation material 26 is planarized or chemically mechanically polished to achieve a desired thickness of material 26 over chip 22 .
- FIG. 4D is a schematic cross-sectional view of chip 22 partially encapsulated by encapsulation material 26 .
- encapsulation material 26 is co-planar with first main face 30 of chip 22 .
- FIG. 5 is a schematic cross-sectional view of semiconductor package units 130 fabricated according to embodiments described above in FIGS. 4A-4D to include multiple semiconductor chips 22 a, 22 b, 22 c . Each of these multiple semiconductor chips 22 a, 22 b, 22 c include one or more through-connections 24 extending between main faces of the chips. Encapsulation material 26 covers at least a portion of the chips after the carrier 120 ( FIG. 4C ) is removed. In one embodiment, the package units 130 are configured for separation or singulation along saw streets 132 . Sawing or dicing along saw streets 132 separates individual components 130 for subsequent fabrication into package 20 or package 40 , as described above.
- FIG. 6 is a schematic cross-sectional view of semiconductor device 40 fabricated according to the manufacturing process described above.
- the embedded chip 22 illustrated in FIG. 4D or the embedded chips 22 a, 22 b, 22 c of the semiconductor units 130 illustrated in FIG. 5 are each suited for subsequent processing to include upper and lower metal layers connected with through-connections 24 / 44 .
- semiconductor chip 22 / 42 is at least partially embedded in encapsulation material 26 and further processed to include upper metal first layers 28 / 48 electrically connected to through-connections 24 / 44 , and lower or second metal layer 60 electrically connected to through-connections 24 / 44 .
- the Z-direction electrical connectivity through the semiconductor package 40 is supplemented with TMV 74 formed to extend through encapsulation material 26 between first metal layer 28 / 48 and second metal layer 60 .
- semiconductor package 40 is configured for use as a base package in a package-on-package system by connecting second metal layer 60 to a printed circuit board, for example with solder balls or other suitable connecting elements.
- semiconductor package 40 is a memory package or a logic package and configured for mounting to a base package in a package-on-package system.
- FIG. 7 is a schematic cross-sectional view of a semiconductor package-on-package (POP) stack 140 according to one embodiment.
- POP stack 140 includes base semiconductor package 40 electrically connected to a printed circuit board 142 , and another package 144 stacked on base semiconductor package 40 .
- solder balls 70 connect second metal layer 60 of base package 40 to printed circuit board 142 .
- Second package 144 or top package 144 is electrically connected to landing pads provided by first metal layer 28 / 48 . In this manner, electrical connection is established between second package 144 through landing pads 28 / 48 , TSV 24 / 44 , second metal layer 60 , solder balls 70 , and ultimately to printed circuit board 142 .
- first metal layer 28 / 48 and second metal layer 60 are patterned redistribution layers patterned over an embedded chip 22 to provide an embedded package-on-package (ePOP) device 140 .
- ePOP embedded package-on-package
- base package 40 is provided as a logic device and second package 144 is provided as a memory device.
- base semiconductor package 40 is provided as a first memory device and second package 144 is provided as a second memory device.
- Printed circuit board 142 includes electronic boards, printed circuit boards, or other suitable electronic devices which POP 40 / 144 is electrically connected.
- Embodiments provide a semiconductor package including one or more semiconductor chips provided with one or more through-silicon vias. Forming the via in the silicon portion of the chip provides a very uniform via as compared to through-mold vias.
- Through-mold vias have openings formed in the encapsulation material, which is typically highly filled with silica particles. The TMV are consequently formed to have a greater width compared to the TSV to account for the undercuts that are formed in the encapsulation material when the opening is formed.
- Embodiments provide an embedded wafer level semiconductor package including through-silicon vias having three-dimensional interconnect geometry, smaller package sizes as compared to wire bonded packages, and improved radio-frequency with reduced power consumption.
Abstract
Description
Claims (22)
Priority Applications (2)
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US20170373029A1 (en) * | 2016-06-23 | 2017-12-28 | Samsung Electro-Mechanics Co., Ltd. | Fan-out semiconductor package |
US10229865B2 (en) * | 2016-06-23 | 2019-03-12 | Samsung Electro-Mechanics Co., Ltd. | Fan-out semiconductor package |
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DE102010000269A1 (en) | 2010-08-19 |
US20100193928A1 (en) | 2010-08-05 |
DE102010000269B4 (en) | 2021-03-18 |
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